02 - Clutch

AR25.10-W-0050GB Remove/install clutch 19.3.07

MODEL 930, 932, 934 with ENGINE 541.9, 542.9
except CODE (G02) Torque converter clutch (WSK)
except CODE (N56) Transmission independent power take-off (NMV) i = 1.48
except CODE (N57) Transmission independent power take-off (NMV) i = 1.09
with double-plate clutch
MODEL 933 with ENGINE 541.9
except CODE (N56) Transmission independent power take-off (NMV) i = 1.48
except CODE (N57) Transmission independent power take-off (NMV) i = 1.09
with double-plate clutch

1 Clutch pressure plate unit

2 Screwdriving
3 Centering drift

W25.10-1047-11

W25.10-1046-09

4 Flywheel 7 Clutch plate (at transmission end) 10 Clutch operator with release bearing
5 Clutch plate (at engine end) 8 Clutch pressure plate 11 Guide bearing
6 Intermediate ring with intermediate 9 Bolt
disk

Modification notes
1.9.06 Before installation of the new clutch pressure plate check Step 11
whether the diaphragm spring reeds are correctly seated
into the clutch bearing, added.

Removing

© Daimler AG, 7/2/13, G/03/13, ar25.10-w-0050gb, Remove/install clutch Page 1 of 2

MODEL 930, 932, 934 with ENGINE 541.9, 542.9 except CODE (G02) Torque converter clutch (WSK) except CODE (N56) Transmission independent power take-off (NMV) i = 1.48 except CODE ...
1 Remove engine or transmission
2 Install assembly device on clutch pressure
plate unit (1)
3 Unscrew bolts (2), lift out clutch pressure
plate unit (1) using the assembly device and
remove clutch plate (5) at engine end
4 Remove assembly device
5 Check clutch parts for wear and damage
Clean
6 Clean profile grooves in the clutch plate (5)
at the engine end and clean hub profile of
the transmission input shaft
7 Clean sliding sleeve in clutch operator with
release bearing (10) and guide tube at
transmission
8 Clean guide bearing (11) in flywheel (4)
Install
9 Slide the centering drift (3) into the guide
bearing (11) in the flywheel (4)
10 Center the clutch plate (5) at the engine end
on the flywheel (4) via the centering drift (3)
11 Install assembly device on clutch pressure
plate unit (1)
12 Install assembled clutch pressure plate unit
(1) with the assembly device over the
centering drift (3)
13 Tighten the bolts (2) in small stages in a
crosswise pattern
14 Remove assembly device
15 Remove centering drift (3)
16 Install engine or transmission
17 Connect STAR DIAGNOSIS
18 Teach in clutch travel anew in the drive
control (FR) control unit
19 Teach in gear control (GS) control unit
20 Disconnect STAR DIAGNOSIS
Select the procedure according to the
setup and accessibility.
Loosen the bolts (2) in small stages
diagonally in order to avoid a one-sided load
on the clutch pressure plate unit (1).
The clutch plates (5 and 7) may only be AR25.10-W-0051BA
replaced together.
The nickel plated hub surface of the
clutch plate (5) must not be greased in order
to avoid the clutch plate (5) jamming.
*950589006100
Before installing the new clutch pressure
plate unit (1) check whether the tongues of
the diaphragm spring seat correctly in the
clutch operator with clutch bearing (10).
A new clutch pressure plate unit (1) is
supplied adjusted.
While tightening ensure that centering
drift (3) can still be moved easily.
*BA25.10-N-1001-01C
Only on vehicles without code (GE2)
Electronic drive control II and without code
(GE3) Mercedes PowerShift.
Only on vehicles with code (GS7) Gear AR54.21-W-0009A
control II, with code (GE2) electronic drive
control II or with code (GE3) Mercedes
PowerShift when the clutch pressure plate
unit (1) or the two clutch plates (5, 7) have
been replaced.

Clutch

Number Designation Engines

541.9, 542.9

BA25.10-N-1001-01C Clutch pressure plate to flywheel Nm 60

950 589 00 61 00
Centering drift

© Daimler AG, 7/2/13, G/03/13, ar25.10-w-0050gb, Remove/install clutch Page 2 of 2

MODEL 930, 932, 934 with ENGINE 541.9, 542.9 except CODE (G02) Torque converter clutch (WSK) except CODE (N56) Transmission independent power take-off (NMV) i = 1.48 except CODE ...
AR25.19-W-0100B Remove/install clutch travel sensor 9.6.11
MODEL 930, 932, 933, 934 with CODE (GE2) Electronic drive control II
MODEL 375.4, 930, 932, 933, 934, 940, 944 with CODE (GE3) Mercedes PowerShift
MODEL 930, 932, 933, 934 with CODE (GE7) Mercedes PowerShift 2

1 Electrical connector
2 Electrical connector

B2 Clutch travel sensor

W25.19-1011-11

3 Bolts
4 Retaining plate

B2 Clutch travel sensor

W25.19-1012-11

Modification notes
16.5.11 Repair materials for clutch booster with plastic housing Operation step 3 *BR00.45-Z-1033-02A
added.

Remove/install
1 Disconnect electrical connector (2)
2 Disconnect electrical connector (1) from
clutch travel sensor (B2)
3 Remove bolts (3) from clutch travel sensor Installation: Insert screws (3) with
(B2) instant-set adhesive:

For clutch booster with metallic housing *BR00.45-Z-1008-02A

For clutch booster with plastic housing *BR00.45-Z-1033-02A
*BA25.20-N-1004-01J
4 Remove clutch travel sensor (B2) with Installation: Replace the sealing rings on
retaining plate (4) the clutch travel sensor (B2).
5 Install in the reverse order
6 Perform minor teach-in process AR54.21-W-0009A

Clutch booster

© Daimler AG, 7/2/13, G/03/13, ar25.19-w-0100b, Remove/install clutch travel sensor Page 1 of 2
MODEL 930, 932, 933, 934 with CODE (GE2) Electronic drive control II MODEL 375.4, 930, 932, 933, 934, 940, 944 with CODE (GE3) Mercedes PowerShift MODEL 930, 932, 933, 934 with ...
 Number Designation Model Model Model
374.607/ 930, 932, 940, 942,
691/695, 933, 934 943, 944
375.4

BA25.20-N-1004-01J Bolt, clutch travel sensor to clutch booster Nm 5 5 5

Repair materials

Number Designation Order number

BR00.45-Z-1008-02A
BR00.45-Z-1033-02A
Quick-acting adhesive, Loctite 270 A 002 989 93 71
Quick-acting adhesive, Loctite 495 Henkel Loctite Deutschland GmbH
Arabellastrasse 17
D-81925 Munich
Germany
Tel. +49 899268-0
Fax +49 899101978
www.Loctite.de

© Daimler AG, 7/2/13, G/03/13, ar25.19-w-0100b, Remove/install clutch travel sensor Page 2 of 2
MODEL 930, 932, 933, 934 with CODE (GE2) Electronic drive control II MODEL 375.4, 930, 932, 933, 934, 940, 944 with CODE (GE3) Mercedes PowerShift MODEL 930, 932, 933, 934 with ...
AR25.20-W-0300EA Clutch servo unit removal and installation 15.6.09
MODEL 930, 932, 933, 934
with CODE (IY2) Hydraulic fluid as per sheet 345.0
except CODE (GE2) Electronic drive control II
except CODE (GE3) Mercedes PowerShift
except CODE (GE7) Mercedes PowerShift 2
MODEL 942, 943, 958.4 with CODE (IY2) Hydraulic fluid as per sheet 345.0
MODEL 375.4, 940, 944
with CODE (IY2) Hydraulic fluid as per sheet 345.0
except CODE (GE3) Mercedes PowerShift
MODEL 374.6 with TRANSMISSION 715.5 with CODE (IY2) Hydraulic fluid as per sheet 345.0

W25.20-1020-09

1 Plunger 4 Compressed-air line 8 Sealing ring

2 Clutch servo assistance 5 Fuse 9 Banjo bolt
3 Clutch travel sensor connector 6 Hydraulic line 10 Sealing ring
7 Banjo union (compressed air line) 11 Connector
2 Clutch servo assistance
3 Clutch travel sensor connector
4 Compressed-air line
6 Hydraulic line
12 Compressed air line bracket
13 Electrical connector

W25.20-1055-12

Remove/install

© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0300ea, Clutch servo unit removal and installation Page 1 of 2
MODEL 930, 932, 933, 934 with CODE (IY2) Hydraulic fluid as per sheet 345.0 except CODE (GE2) Electronic drive control II except CODE (GE3) Mercedes PowerShift except CODE (GE7) ...
 Notes on hydraulic fluid as per Specification, AH00.40-N-0002-01A
Sheet 345.0
1 Drain reservoir pressure of compressed air
system
2 Separate clutch travel sensor connector (3)
3 Detach compressed air line bracket (12)
4 Detach compressed-air line (4) Counterhold at the banjo bolt (9) when
loosening the compressed air line (4).
*BA25.20-N-1010-01J
5 Unscrew the banjo bolt (9) *BA25.20-N-1003-01J
6 Remove locking device (5) from connector Collect hydraulic fluid which runs out with
(11) and detach hydraulic line (6) a suitable container.
7 Disconnect electrical connector (13)
8 Remove clutch servo unit (2) *BA25.20-N-1001-01J
9 Remove plunger (1) Installation: Clean ball head and guide of *BR00.45-Z-1001-06A
plunger (1) and grease with long-life grease.
10 Detach connector (11) Only when replacing the clutch booster
(2).
*BA25.20-N-1003-01J
11 Install in the reverse order
12 Bleed clutch operating system AR25.20-W-0070FA

Clutch booster

Number Designation Model Model Model Model

374.607/ 930, 932, 940, 942, 958.4
691/695, 933, 934 943, 944
375.4

BA25.20-N-1001-01J Bolt, clutch booster to transmission housing Nm 50 50 50 50

BA25.20-N-1003-01J Banjo bolt (compressed-air line) to clutch Nm 40 40 40 40

booster

BA25.20-N-1010-01J Union nut (compressed-air line) at clutch Nm 40 40 40 40

booster

Repair materials
Number Designation Order number
BR00.45-Z-1001-06A Long-life grease A 000 989 63 51 11

© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0300ea, Clutch servo unit removal and installation Page 2 of 2
MODEL 930, 932, 933, 934 with CODE (IY2) Hydraulic fluid as per sheet 345.0 except CODE (GE2) Electronic drive control II except CODE (GE3) Mercedes PowerShift except CODE (GE7) ...
AR25.20-W-0200G Remove and install clutch throwout lever 12.7.10
MODEL 933
MODEL 930, 932, 934 except CODE (G02) Torque converter clutch (WSK)

1 Release lever
2 Plunger
3 Bearing sleeve
4 Retaining ring
5 Washer
6 Bearing sleeve
7 Bearing axis
8 Guide rollers

Arrows Bearing points

W25.20-1081-05

Modification notes
18.3.10 Tightening torque for vehicles with code (GK8) Turbo Operation step 7 *BA25.20-N-1014-01B
clutch, added.

Removing
1 Remove engine, transmission or turbo clutch Select the procedure according to the
with transmission setup and accessibility.
2 Remove release lever (1)
3 Remove lifter (2) from release lever (1)
Checking
4 Check bearing bushing (3) of plunger (2) for If necessary, replace bearing bushing (3).
wear and damage
5 Check bearing bushings (6), bearing shaft If necessary, replace release lever (1) or
(7) and guide rollers (8) for wear and disassemble release lever (1) and replace
damage worn or damaged parts.
Install
6 Install lifter (2) into release lever (1)
7 Install release lever (1) Grease bearing points (arrows) lightly. *BR00.45-Z-1062-06A
Vehicles without code (GK8) Turbo *BA25.20-N-1001-01B
clutch
Vehicles with code (GK8) Turbo clutch *BA25.20-N-1014-01B
8 Install engine, transmission or turbo clutch
with transmission

Clutch operating mechanism

Number Designation Engine 541.9,

542.9

BA25.20-N-1001-01B Release lever to transmission Nm 75

BA25.20-N-1014-01B Release lever to turbo clutch Nm 75

Repair materials
Number Designation Order number
BR00.45-Z-1062-06A Lubricating grease, Olista Longtime, DB supply specification 6804.60 A 001 989 36 51 10

© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0200g, Remove and install clutch throwout lever Page 1 of 1
MODEL 933 MODEL 930, 932, 934 except CODE (G02) Torque converter clutch (WSK)
AR25.20-W-3000B Remove/install clutch actuator 12.7.10
MODEL 930, 932, 934
with CODE (GE3) Mercedes PowerShift
with CODE (GK8) Turbo clutch

1 Clutch actuator
2 Vent valve
3 Cover
4 Electrical connector
5 Electrical connector
6 Compressed-air line
7 Banjo bolt
8 Banjo union (compressed air)

W25.20-1107-06

Removing
Danger! Risk of injury caused by body parts being Always remove the ignition key and vent the AS25.00-Z-0001-01A
trapped or crushed when working on the clutch actuator before removing clutch
pressurized clutch actuator actuator.
1 Withdraw ignition key
2 Drain reservoir pressure of compressed air
system
3 Disconnect electrical connectors (4, 5)
4 Remove clamp for compressed-air line (6)
from transmission
5 Detach air line (6) from banjo bolt (7) Counterhold at the banjo bolt (7) when
loosening the compressed air line (6).
6 Unscrew banjo bolt (7)
7 Unscrew cover (3) and press in the bleed pin As a result an adjustment is produced
in the vent valve (2) (arrow) between atmospheric pressure and the
pressure in the clutch actuator (1).
8 Remove clutch actuator (1)
Install
9 Adjust plunger of clutch actuator (1) Only when installing a new clutch or a AR25.20-W-3000-01B
new plunger.
*BA25.20-N-1011-01J
*930589002300
Bolt for adjusting device WF58.50-W-2520-01A
10 Press in the bleed pin in the bleed valve (2) Afterwards release the bleed pin and hold
(arrow) and simultaneously press the piston the piston rod of the clutch actuator (1)
rod of the clutch actuator (1) into the clutch securely in the retracted position.
actuator (1)
11 Install clutch actuator (1) *BA25.20-N-1012-01J
12 Screw down cover (3) securely
13 Install banjo bolt (7) with banjo union (8) *BA25.20-N-1008-01J
14 Fit air line (6) to banjo bolt (7) When tightening counterhold the banjo
bolt (7).
*BA25.20-N-1009-01J
15 Fit clamp for compressed-air line (6) to
transmission
16 Connect electrical connectors (4, 5)

© Daimler AG, 7/2/13, G/03/13, ar25.20-w-3000b, Remove/install clutch actuator Page 1 of 2

MODEL 930, 932, 934 with CODE (GE3) Mercedes PowerShift with CODE (GK8) Turbo clutch
 Clutch booster

Number Designation Model

930, 932,
933, 934

BA25.20-N-1008-01J Banjo bolt (compressed-air line) to clutch Nm 40

actuator

BA25.20-N-1009-01J Union nut (compressed-air line) at clutch Nm 40

actuator

BA25.20-N-1011-01J Jam nut to plunger of clutch actuator Nm 40

BA25.20-N-1012-01J Bolt, clutch actuator to turbo clutch Nm 50

930 589 00 23 00
Adjusting device

© Daimler AG, 7/2/13, G/03/13, ar25.20-w-3000b, Remove/install clutch actuator Page 2 of 2

MODEL 930, 932, 934 with CODE (GE3) Mercedes PowerShift with CODE (GK8) Turbo clutch
AR25.20-W-0110A Remove/install electromotive clutch (EMK) 13.11.08
ENGINES 541.92, 542.92 with CODE (GE1) Electronic drive control

1 Electromotive clutch (EMK)

2 Cover
3 Screw
4 Screw
5 Screw
6 Supply line
7 Fuse
8 Hydraulic line
9 Collar bolt
10 Nut
X5 Connector for electromotive clutch
(EMK)

W25.20-0003-06

Modification notes
26.7.99 Programming EPS control unit Operation step 14

Remove/install
1 Switch off ignition
2 Open maintenance flap
Danger! Risk of poisoning caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A
brake fluid. Risk of injury caused by brake appropriately marked containers. Wear
fluid coming into contact with skin and eyes. protective clothing and eye protection when
handling brake fluid.
3 Extract brake fluid from master cylinder
expansion reservoir
Brake fluid notes All models AH42.50-P-0001-01A
4 Disconnect connector (X5)
5 Cut cable ties (arrows) Installation: Replace cable ties.
6 Take off cover (2)
7 Remove bolt (4) and detach connection of
circuit 30
8 Remove bolt (5) and disassemble ground
connection
9 Detach supply line (6) on master cylinder Collect escaping brake fluid using a
suitable container.
Installation: The supply line (6) must
engage securely in the rubber grommet of
the master cylinder.
10 Remove retainer (7) and detach hydraulic In the event of sluggishness grasp
line (8) hydraulic line (8) at the front on the metal
piece using suitable pliers, loosen by light
rotary motions and press downwards.
Collect escaping brake fluid using a
suitable container.
11 Detach electromotive clutch (1) from bracket *BA25.20-N-1004-01B
12 Install in the reverse order
13 Bleed clutch operating system AR25.20-W-0070B
14 Teach in EPS control unit AR54.21-W-0007A

Clutch operating mechanism

© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0110a, Remove/install electromotive clutch (EMK) Page 1 of 2
ENGINES 541.92, 542.92 with CODE (GE1) Electronic drive control
 Number Designation Engine 541.9,
542.9

BA25.20-N-1004-01B Bolt of electromotive clutch (EMK) to body Nm 30

© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0110a, Remove/install electromotive clutch (EMK) Page 2 of 2
ENGINES 541.92, 542.92 with CODE (GE1) Electronic drive control
AR25.20-W-0100D Remove/install master cylinder 15.6.09
MODEL 930, 932, 933, 934
except CODE (GE2) Electronic drive control II
except CODE (GE3) Mercedes PowerShift
except CODE (GE7) Mercedes PowerShift 2

1 Left footwell cover

2 Center footwell cover
3 Nut
4 bearing bolt
5 Bolts
6 Floor Covering

W25.20-1073-12

7 Expansion reservoir
8 Screw
9 Master cylinder
10 Fuse
11 Hydraulic line

W25.20-1074-12

Remove/install
Danger! Risk of poisoning caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A
brake fluid. Risk of injury caused by brake appropriately marked containers. Wear
fluid coming into contact with skin and eyes. protective clothing and eye protection when
handling brake fluid.
Brake fluid notes AH42.50-P-0001-01A
Notes on hydraulic fluid as per Specification, AH00.40-N-0002-01A
Sheet 345.0
1 Fold back floor covering (6)
2 Remove left footwell cover (1)
3 Remove center footwell cover (2)

© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0100d, Remove/install master cylinder Page 1 of 2

MODEL 930, 932, 933, 934 except CODE (GE2) Electronic drive control II except CODE (GE3) Mercedes PowerShift except CODE (GE7) Mercedes PowerShift 2
4 Remove nut (3) and bearing bolt (4) Installation: Grease the bearing bolt (4) *BR00.45-Z-1001-06A
and replace the nut (3).
Notes on self-locking nuts and bolts AH00.00-N-0001-01A
5 Remove bolts (5) *BA25.20-N-1002-01B
6 Open maintenance flap
7 Remove bolt (8) from expansion reservoir (7) *BA25.20-N-1003-01B
8 Remove master cylinder (9) with expansion
reservoir (7) forwards
9 Empty expansion reservoir (7) Collect hydraulic fluid with a suitable
container.
10 Remove retainer (10) from master cylinder Installation: Install new retainer (10).
(9)
11 Detach hydraulic line (11) from master In the event of sluggishness loosen the
cylinder (9) hydraulic line (11) at the metal fitting with
slight rotary motions and pull out. Collect
hydraulic fluid which runs out with a suitable
container.
12 Detach expansion reservoir (7) from master Installation: The expansion reservoir (7)
cylinder (9) by twisting slightly must engage in the rubber grommet of the
master cylinder (9).
13 Install in the reverse order
14 Bleed clutch operating system Vehicles without code (IY2) Hydraulic fluid AR25.20-W-0070F
as per sheet 345.0
Vehicles with code (IY2) Hydraulic fluid as AR25.20-W-0070FA
per sheet 345.0

Clutch operating mechanism

Number Designation Engine 541.9,

542.9

BA25.20-N-1002-01B Bolt, master cylinder to pedal bracket Nm 10

BA25.20-N-1003-01B Bolt, expansion reservoir (master cylinder) to Nm 10

pedal bracket

Repair materials

Number Designation Order number

BR00.45-Z-1001-06A Long-life grease A 000 989 63 51 11

© Daimler AG, 7/2/13, G/03/13, ar25.20-w-0100d, Remove/install master cylinder Page 2 of 2

MODEL 930, 932, 933, 934 except CODE (GE2) Electronic drive control II except CODE (GE3) Mercedes PowerShift except CODE (GE7) Mercedes PowerShift 2